Multi-Speed Electric Transmission Common Carrier Design
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Solution Overview
Problem
Existing hybrid powertrain configurations for vehicles require complex packaging and increased manufacturing inefficiencies due to the need for shafts to be inserted through other shafts to connect carrier gears to sun gears across different planetary gears, leading to increased packaging constraints.
Innovation Solution
A multi-speed electric transmission assembly featuring a first shaft coupled to an electric motor generator with a planetary gear assembly, a second shaft coupled to a Ravigneaux gear assembly with a common carrier engaging both planetary gear sets, and a ring gear outputting torque to an electric axle assembly, reducing packaging size and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If shafts are inserted through other shafts to connect carrier gears to sun gears across different planetary gears, then the powertrain can achieve multiple operating modes and power sources, but the packaging size increases and manufacturing efficiency decreases
Solution Approach 1:
The patent combines multiple planetary gear sets (first and second planetary gear sets) around a common carrier, eliminating the need for separate shafts to connect them. This merging of gear sets onto a single carrier structure reduces the overall packaging volume while maintaining the ability to achieve multiple operating modes through clutch and brake engagement.
Solution Approach 2:
The common carrier serves multiple functions by supporting both the first and second planetary gear sets, replacing what would traditionally require separate shafts and connection mechanisms. This multi-functional carrier reduces packaging constraints while enabling versatile powertrain operation through different gear ratio selections.
2Adaptability or versatility
If shafts are inserted through other shafts to connect carrier gears to sun gears across different planetary gears, then the powertrain can achieve multiple operating modes, but manufacturing efficiency decreases
Solution Approach 1:
By merging multiple planetary gear sets onto a single common carrier, the patent eliminates complex shaft insertion and alignment operations that would be required to connect separate gear sets. This simplifies the manufacturing process and improves production efficiency while maintaining the capability for multiple operating modes through clutch and brake control.
3Volume of stationary object
If a compact transmission assembly is used to reduce packaging size, then the physical space requirements decrease, but the complexity of connecting shafts across planetary gears increases
Solution Approach 1:
The patent merges multiple planetary gear sets onto a single common carrier, which inherently simplifies the connection architecture. Instead of requiring multiple shafts to connect separate gear sets, the common carrier provides a unified structural platform that reduces connection complexity while achieving compact packaging.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables a compact and efficient powertrain with enhanced accessibility, allowing for three gear ratios in a smaller package, reducing physical space requirements and manufacturing inefficiencies while maintaining performance.
Implementation Method 1
a first gear assembly mechanically coupled to the first shaft. The first gear assembly comprises a first planetary gear assembly comprising a first planet gear set
Implementation Method 2
a second gear assembly, different than the first gear assembly, wherein the second gear assembly comprises a second planet gear set and a third planet gear set, wherein a carrier is engaged with each of the first planetary gear set and the second planetary gear set
Data Source
AI summary
Methods and systems are provided for an electric axle assembly. In one example, a system includes an electric axle assembly configured to receive an output of a ring gear, wherein a differential of the electric axle assembly distributes the output to wheels of a vehicle.